Method and apparatus for forming variable cut and/or loop pile tufts over level cut loop tufts

ABSTRACT

A tufting machine including spaced rows of needles for inserting yarns into a backing material. The needles are engaged by a series of cut pile hooks and level cut loop loopers or hooks that generally are arranged at spaced elevations. The cut pile hooks will engage one of the rows of needles for forming cut pile tufts of yarns in the backing material. The level cut loop loopers or hooks engage the other row of needles and each include clips. The clips are selectively moved into a position substantially blocking retention of loops of yarns picked up and/or formed along their level cut loop loopers or hooks for formation of loop and cut pile tufts of yarns in the backing material.

CROSS REFERENCE TO RELATED APPLICATIONS

The present patent application is a formalization of previously filed, co-pending U.S. Provisional Patent Application Ser. No. 62/032,108, filed Aug. 1, 2014 by the inventors named in the present application. This patent application claims the benefit of the filing date of this cited Provisional patent application according to the statutes and rules governing provisional patent applications, particularly 35 U.S.C. §119(e), and 37 C.F.R. §§1.78(a)(3) and 1.78(a)(4). The specification and drawings of the Provisional patent application referenced above are specifically incorporated herein by reference as if set forth in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to tufting carpets, and in particular to a method and system for tufting loop, cut, and level cut loop tufts of yarn in a backing material to form patterned carpets.

BACKGROUND OF THE INVENTION

In the field of tufting carpets, it has been known to tuft carpets having spaced rows of loop pile and cut pile tufts, including the formation of loop pile tufts and cut pile tufts in the same longitudinal tuft rows of the carpets. For example, U.S. Pat. Nos. 5,224,434 and 5,499,588 disclose a multi-needle tufting machine having two transverse rows of needles with each row cooperating with a series of loop pile loopers or cut pile hooks for producing cut pile and loop pile tufts in the same longitudinal rows of tufting and with the needle bars carrying spaced rows of needles being shifted to provide enhanced pattern effects such as the formation of cut and loop pile tufts in the same tuft rows. For higher or finer gauge tufting machines, i.e., 5/32- 1/16 gauge machines, however, as the spacings between the needles are narrowed for forming finer gauge carpets, there is a potential for the cut pile hooks to engage the previously formed loop and/or cut pile tufts, potentially resulting in the cutting or pulling of such tufts, creating defects in the carpet. Additionally, there are increasing demands for the capability of tufting machines to produce carpets with wider varieties of pattern designs and effects, including at finer gauges.

Accordingly, it can be seen that a need exists for a method and system for variably or selectively forming cut pile tufts over loop and/or cut pile tufts in a backing material to form patterned carpets, and which addresses the foregoing and other related and unrelated problems in the art.

SUMMARY

Briefly, described, the present invention generally relates to a method and apparatus for forming or introducing loop and/or cut pile tufts of yarns at differing or varied pile heights or lengths into a backing or base fabric passing through a tufting zone of a tufting machine to form tufted articles having selectively variable height cut and/or loop pile tufts. The tufting machine generally will include first and second rows of transversely spaced needles that receive a series of yarns from a yarn source or yarn feed drive mechanism. The needles generally are mounted in a laterally spaced arrangement along one or more needle bars at a prescribed gauge spacing, i.e., ½ inch- 1/16 inch, etc., and with the rows of needles further being spaced apart by a desired longitudinal stagger or spacing. For example, the needles can be mounted in rows in a staggered or substantially in-line arrangement along a single needle bar or along a pair of needle bars. The needles are reciprocated into and out of engagement with a backing material passing through a tufting zone of the tufting machine for introduction of tufts of yarns into the backing material to form tufted articles such as carpets. The yarns can be fed to the needles using a variety of yarn fed rolls or systems, including scroll, roll and single or double end yarn feed systems, with the feeding of the yarns controlled to provide varying pattern effects. For example, the yarns can be fed to the needles from an Infinity Yarn Feed System as manufactured by Card-Monroe Corp. The needle bar(s) also can be shifted laterally to provide further pattern effects.

A gauge or looper mechanism is mounted below the backing material and generally includes a spaced series of cut pile hooks, and/or level cut loop loopers or hook assemblies. For example, in one embodiment, a series of cut pile hooks and level cut loop looper or hook assemblies can be mounted in a vertically spaced or stacked arrangement along one side of the tufting zone, with the cut pile hooks being mounted at a first elevation that is different from a second elevation at which the level cut loop hooks are mounted. Each of the cut pile hooks generally will include a body or shank portion attached to a holder or support, and a throat or forwardly extending portion having a hooked forward end. The forward end of each cut pile hook will strike a take-off portion of its associated needle and will pickup and capture a loop of yarn along its throat. Knives associated with each cut pile hook will be reciprocated into engagement with and can sever the loop(s) of yarn captured on the throat portion of each cut pile hook to form a series of cut pile tufts in the backing or base fabric.

The level cut loop looper or hook assemblies each generally will include a level cut loop looper or hook having a shank or body portion and a throat portion that extends forwardly therefrom and terminates in a hooked or curved forward end. Each level cut loop hook also can have a clip movable between retracted and engaging positions by an actuator to enable selective capture of yarns along the throat of its level cut loop hook as needed for forming cut or loop pile tufts, according to the pattern design being tufted. Each level cut loop hook will engage an associated needle at a pickup or takeoff portion thereof so as to pickup and form loops of yarns along the throat portion of the level cut loop or hook. Each level cut loop or hook further generally will include a knife assembly associated therewith, which includes a knife or cutting blade that is moved in a reciprocal cutting motion so as to sever or cut the loops of yarn collected along the throat of its associated level cut loop hook to form an additional or second series of cut pile tufts in the backing material.

In one embodiment of the system of the present invention, the level cut loop hooks and cut pile hooks both can be located on a downstream side of the tufting zone, generally arranged at differing elevations. For example, the cut pile hooks can be mounted at a first elevation spaced above the level cut loop hooks, which can be mounted at a second, lower elevation. The cut pile hooks further generally can be located or arranged in positions aligned with gaps defined between each of the level cut loop hooks, or otherwise offset from the level cut loop hooks arranged therebelow, and with each of the level cut loop hooks similarly generally aligned with a gap defined between adjacent ones of the cut pile hooks. As the needles penetrate the backing, the cut pile hooks and level cut loop or hooks will be reciprocated into engagement with their associated needles of the first and second rows of needles, which also can be of different lengths so as to penetrate the backing at different elevations or penetration depths. For example, the cut pile hooks can be located at a first elevation and can pass through gaps between the second, rear or downstream row of needles to engage the first, front or upstream row of needles at a first penetration depth, while the level cut loop or hooks can be located at a second elevation and can engage the second row of needles at a second penetration depth to enable level cut loop pattern formation and functionality, including formation of cut pile tufts at differing, variable pile heights.

The knives associated with or corresponding to each of the cut pile hooks and/or level cut loop hooks further can be of the same or of an opposite hand cutting to the takeoff or pickup needles of the first row of needles and can be positioned on the pickup side their associated cut pile hooks and/or level cut loop loopers or hooks, so as to be positioned along the same side of their level cut loop hooks or cut pile hooks as the needles being engaged thereby. During operation of the tufting machine, the cut pile hooks and level cut loop hooks are reciprocated into engagement with the rows of needles as the needles penetrate the backing material to form both cut pile and cut or loop tufts of yarns in the backing material. The knives of each of the level cut loop hooks and cut pile hooks will be moved in a reciprocating cutting motion to engage and cut the loops collected along the throat portions of their associated level cut loop hooks and cut pile hooks to form cut pile tufts. Additionally, as the clips of selected ones of the level cut loop hooks are actuated and moved to their engaged position, they can substantially prevent the retention of loops of yarn along the throats of their level cut loop hooks to enable selective formation of loop pile tufts in the backing material. The resultant cut pile and loop pile tufts formed by operation of the cut pile hooks and level cut loop hooks further can be formed with differing pile heights or elevations, such as to provide various desired sculptured effects to the tufted articles being formed.

In other embodiments, a first series of level cut loop loopers or hooks can be used in conjunction with an additional or second series of level cut loop loopers or hooks, with both sets of gauge parts generally being located along the same side of the tufting zone. In one such embodiment, a single row of needles can be provided, and the level cut loop hooks can be arranged in sets or rows located in a vertically staggered configuration, with the first row or series of level cut loop hooks engaging the needles at a first elevation or penetration depth, while the second series or row of level cut loop hooks engages the needles at a second elevation or penetration depth. For example, the upper or first row of level cut loop hooks can be mounted in a support or hook block and can have a raised shank or body portion so that the throats or bill portions thereof are spaced vertically by a desired distance above the throat portions of a lower or second row or group of level cut loop hooks mounted within the same hook block. Alternatively, the hook module or support for the level cut loop hooks can be configured with an expanded height or thickness so as to enable formation of slots at different elevations for receiving the different rows of level cut loop hooks therein. In addition, where multiple rows or sets of level cut loop hooks are used, the level cut loop hooks of the first or uppermost row can have a body portion that is expanded vertically so that the throat portions of such level cut loop hooks are positioned above the throat portions of the lower or second row of level cut loop hooks. In such arrangements, varying levels or pile heights of cut pile and loop pile tufts of yarns can be formed in the same backing material to enable formation of carpets having further enhanced and varying pattern effects.

Various objects, features and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description when taken in conjunction with the accompanying drawings.

DESCRIPTION OF DRAWINGS

FIG. 1 is a side elevational view illustrating the engagement of the level cut loop hook or looper assemblies and cut pile hooks with the rows of needles according to one embodiment of the present invention.

FIG. 2A is a perspective view of one embodiment of a gauging module or assembly utilizing cut pile hooks with level cut loop loopers or hooks for use in a tufting machine as illustrated in FIG. 1.

FIG. 2B is a side elevational view of the gauging module or assembly of FIG. 2A.

FIG. 3 is a side elevational view illustrating the level cut loop loopers or hooks and cut pile hooks of FIGS. 1-2B engaging their associated needles of the rows of needles.

FIG. 4 is a perspective illustration showing the arrangement of the cut pile hooks and level cut loop loopers or hooks for engagement with the spaced rows of needles according to the principles of the present invention.

FIG. 5A is a perspective view illustrating another embodiment of the present invention utilizing two sets or groups of level cut loopers or hooks.

FIG. 5B is a side elevational view of the embodiment of FIG. 5A.

FIG. 6 is a perspective illustration of the interaction between the sets of level cut loop loopers or hooks of FIGS. 5A-5B and their corresponding needles.

FIG. 7 is a side view schematically illustrating a tufted article formed with varying height cut pile and loop pile tufts in accordance with the principles of the present invention.

Those skilled in the art will appreciate and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and that the dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein.

DETAILED DESCRIPTION OF THE INVENTION

Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views, the present invention generally relates to a method and system for forming tufted carpets having loop pile and cut pile tufts of yarns Y1 and Y2 formed therein for forming various sculpted or other patterned effects in the carpet. As illustrated in FIG. 1, in one embodiment, a tufting machine T utilizing the system and method of the present invention will include a tufting zone 10 through which a base fabric or backing material 11 is fed in a feed direction, generally indicated by arrow 12, for the introduction of yarns Y1 and Y2 therein. The yarns Y1/Y2 generally will be fed from a yarn feed device or source, indicated at 15A/15B, through guides 13 for insertion into the backing material 11 to form loop pile tufts 14 (FIG. 1) and cut pile tufts 16, respectively, (including loop and cut pile tufts having different or variable pile heights or levels) in the backing material, such as illustrated in FIG. 7. By way of example, the yarn feed devices could include various yarn feed pattern attachments, such as scroll, roll, single, or double end yarn feed attachments, such as an Infinity™ or Yarntronics™ Pattern attachment/yarn feed system manufactured by Card-Monroe Corp. The yarn feed devices or attachments can further be mounted on one or both sides of the tufting machine and will be operated so as to control the feeding of the yarn to the needles as needed for producing various tufted pattern effects.

The tufting machine T (FIG. 1), in one embodiment, can include spaced rows of needles 17 and 18. Although only one needle of each row of needles 17/18 is shown in FIGS. 1 and 3 for clarity, it will be understood that the needles of each row will be arranged in spaced series transversely across the tufting zone 10 (as indicated in FIG. 4). For example, the needles of each row can be spaced apart at a prescribed gauge spacing of approximately 5/32″, 1/16″, 1/10″, ⅛″, ⅕″ or other spacings, with the rows of needles 17/18 also generally being staggered or separated longitudinally across the tufting zone by about 1/16 inch- 5/32 inch up to about ½ inch or more. In addition, the needles of each row can be arranged in a staggered or offset arrangement with the needles of each row approximately aligned with a spacing defined between the needles of the other row as indicated in FIG. 4. As illustrated in FIGS. 1 and 3, each of the needles generally will include an elongated body 20A/20B with a lower, pointed end 21, a pick-up or take-off area 22 adjacent its pointed end, an eye opening 23, and a channel 24 along which a yarn Y1 or Y2 is received. The first or forwardmost row of needles 17 can carry a series of yarns Y1 as they are reciprocated into and out of the backing 11, while the second or rear row of needles 18 can carry a series of yarns Y2 for introduction into the backing material 11, as shown in FIG. 1.

The needles can be mounted to a pair of reciprocating needle bars 26 as shown in FIGS. 1 and 3 which are driven by the operation of the main shaft of the tufting machine so as to move the needles about a vertically reciprocating path indicated by arrows 27/2′T into and out of the backing material 11 for delivering the yarns Y1-Y2, thereto. The needle bars 26 further can be shiftable needle bars that are shifted transversely across the tufting zone by a shift mechanism according to pattern instructions. Additionally, while two needle bars are shown, it is further envisioned that a single needle bar, which could be shifted transversely and which includes rows of transversely spaced needles mounted in a staggered or a substantially in-line arrangement therealong, also could be utilized.

As further shown in FIGS. 1 and 3, the needles 17 and 18 can include different length bodies 20A/20B and/or can be mounted to their needle bars 26 in a manner such that their pointed ends 21 can extend to and/or can be located at different elevations or penetration depths when extended into the backing material. For example, as indicated in FIG. 3, the first or upstream row of needles 17 can extend to a penetration distance “d” that is less than a penetration distance “D'” of the second or downstream row of needles 18 so that the pointed ends 21 of the needles 17 are at a higher elevation than the needles 18 as the needles are reciprocated along their stroke into and out of the backing material and are engaged by the gauge parts of a looper or hook mechanism 30.

Mounted beneath the tufting zone 10 is the looper or hook mechanism 30, as indicated in FIGS. 1 and 3. The looper or hook mechanism 30 generally includes a series of gauge parts that generally can be mounted at varying, different elevations, including, in the illustrated embodiment, a series of level cut loop looper or hook assemblies 31 mounted in series along a downstream side of a tufting zone and generally facing toward an opposite direction 12 of feeding of the backing material 11. The looper or hook mechanism 30 also includes a series of transversely spaced cut pile hooks 32 also generally positioned along the downstream side of the tufting zone and facing in a direction opposite the feed direction 12. It will be understood by those skilled in the art that while only a few level cut loop looper or hook assemblies and cut pile hooks have been illustrated in the drawings for clarity, a series of level cut loop looper or hook assemblies and cut pile hooks will be provided, extending in spaced series across the width of the tufting zone of the tufting machine, with the number of level cut loop looper or hook assemblies and cut pile hooks generally being based upon the size of the tufting machine and number of needles of each row of needles. As also illustrated in FIGS. 1-4, the cut pile hooks can be mounted at a first elevation while the level cut loop hooks can be mounted at a second elevation that is different from the first elevation at which the cut pile hooks are mounted.

As illustrated in FIGS. 1-3, each of the level cut loop hook assemblies 31 can comprise a level cut loop hook 33 that includes a body or shank 34 portion mounted within a holder, support or module 36 (FIGS. 1-2B) that in turn will be mounted along a gauge bar 37 (FIGS. 1 and 3). The gauge bar 37 can have a series of holders or supports 36 mounted thereto for locating the level cut loop assemblies along the gauge bar, and will be driven by a drive mechanism 38 so as to carry the level cut loop hooks 33 about a reciprocal motion, indicated by arrows 39 and 39′, into and out of engagement with an associated one of the needles 18 of the second row of needles. Each of the level cut loop hooks 33 also can include an elongated throat portion 41 projecting forwardly from its shank 34 and terminating in a hooked forward or distal end 42 as indicated in FIGS. 2A-2B. The level cut loop hooks each further can include a pickup side 43 for engaging the takeoff or pickup area 22 of their associated needles 18.

As additionally shown in FIGS. 1-3, each of the level cut loop hook assemblies 31 also will include an extensible clip 45 that is movable through holders 36 and along the body or shank 34 of each level cut loop hook 33 in the direction of arrows 46 and 46′ between a retracted position and an extended position. Each clip 45 can include an elongated body 47, generally formed from metal, plastic, or other rigid, durable material, with a tapered first or forward end 48 and a second or rear end 49 that can be received within a gate 51 (FIG. 3) or similar connector. As indicated in FIGS. 1 and 3, in one embodiment, each gate 51 can have an upwardly or downwardly slanting front portion 52, with a slot 53 formed therein for receiving the rear end 49 of a clip 45, and a rear portion 54.

Actuators, such as hydraulic or pneumatically operable cylinders or other actuators 56, can be mounted in an array (FIGS. 3-4) behind the rear portions 54 of the gates 51, with the cylinder rod 57 of each cylinder attached to a corresponding gate for one of the level cut loop hook assemblies 31. As the actuators are engaged and extend their cylinder rods, the associated gates 51 coupled thereto accordingly are extended so as to move selected ones of the clips 45 toward their extended positions wherein their front ends or tips 48 generally will be positioned adjacent the hooked forward ends 42 (FIGS. 1-2B) of their level cut loop hooks or loopers 33. In this position, the throat portion 41 or area 58 (FIG. 2B) behind the hooked forward end of such selected level cup loop hooks can be substantially closed off so as to cause the loops of yarns picked up thereby to be released or to otherwise generally retard or prevent loops of yarns from being retained therealong, and can thus form a series of loop pile tufts of a desired pile height.

Thus, as indicated in FIGS. 1 and 3, as the needles 18 are reciprocated to their lowered, engaging position, penetrating in the backing material, the hooked front ends of each of the level cut loop hooks 33 will be reciprocated into engagement with the takeoff portions 21 of their associated needles 18 so as to pick up and pull the yarns away from the needles 18. As the needles generally begin to move along their return stroke, the level cut loop hooks 33 will be moved rearwardly in the direction of arrow 39′, and if their clips 45 are in a retracted position, a series of loops of yarn 61 will be formed and/or captured along the throat portions 41 of the level cut loop hooks. These captured or retained loops of yarn formed along the throats of the level cut loop hooks, thereafter can be engaged or cut by corresponding knife assemblies 70 to form cut pile tufts 16 of a desired pile height as indicated in FIGS. 1 and 3.

Additionally, the actuators 56 of the level cut loop looper or hook assemblies 31 also can be engaged selectively to form loop pile tufts 14 as required by the pattern being formed. As the selected actuators are engaged, they can extend their cylinder rods so as to cause the clips 45 of selected ones of the level cut loop hooks 33 to be moved to their extended positions, whereby the loops of yarn picked up or formed about the forward ends of the level cut hooks and their clips and are kept from being captured and retained along the throat portions 41 of such selected level cut loop hooks 33. As the level cut loop hooks thereafter are reciprocated rearwardly in the direction of arrow 39′, the loops 61 of yarns formed about the front ends of the clips and level cut loop hooks can be allowed to be pulled off the level cut loop hooks and thus will not be engaged and cut by the knife assemblies 10, so as to selectively form a series of loop pile tufts 14 as shown in FIG. 3.

As further illustrated in FIGS. 1-4, each level cut loop hook assembly 31 generally has a knife assembly 70 associated therewith. Each knife assembly 70 includes a cutting blade or knife 71 having a cutting edge 72 and being mounted in a holder 73 (FIGS. 1 and 4) so as to be located adjacent the throat portion 41 of its associated level cut loop hook 33. Each of the cutting blades 71 are reciprocated about a cutting path along the throat portion of an associated one of the level cut loop hooks 33, so as to engage and sever the loops of yarn 61 (FIG. 3) formed along the throat portion of each level cut loop hook in order to form cut pile tufts 16 in the backing material 11.

The knives of each knife assembly 70 can be of the same “hand” cutting as the level cut loop hook, i.e., a right hand cutting blade for a right hand takeoff level cut loop hook, or a left hand cutting blade for a left hand takeoff level cut loop hook, and generally will be positioned on the opposite side of the takeoff or pickup region of the loop pile loopers. Alternatively, the level cut loop hook assemblies of the present invention can be of an opposite hand cutting to the pickup of their associated level cut loop hooks 33. For example, if the level cut loop hook is a left hand pickup hook, a right hand cutting blade or knife can be used, and conversely, for a level cut loop hook having a right hand pickup hook, a left hand cutting knife can be used. The knives 71 further can be mounted along the pickup side of their level cut loop hooks, so as to be generally aligned with and thus on the same side of their level cut loop hooks as their respective needles 18 as the needles are engaged by their associated level cut loop hooks. It is also possible, however, to have the needles positioned on the opposite sides of the level cut loop hooks from the knives.

As further shown in FIGS. 2A and 2B, in one embodiment of the method and system for forming tufted carpets having loop pile and cut pile tufts of yarns according to the principles of the present invention, a series of cut pile hooks 32 can be mounted adjacent each of the level cut loop looper or hook assemblies 31. In one embodiment, the cut pile hooks can be arranged along the downstream side of the tufting zone of the tufting machine, in a position or at an elevation or location vertically spaced from the level cut loop looper or hook assemblies, i.e. being spaced above the level cut loop hooks by a desired separation or spacing distance to create a desired pile height differential, as illustrated in FIGS. 1 and 3. As further shown in FIG. 2A, the cut pile hooks 32 and level cut loop hooks 33 can be mounted in a vertically spaced or separated arrangement within a common support block or holder 36, which can have a body 81 with a front face 82, a rear face 83, and a lower portion 84. The lower portion 84 additionally can include a bore or fastener opening 86 extending therethrough and can be configured to seat upon a hook bar (as indicated in FIGS. 1 and 3) for the drive mechanism as discussed above. Alternatively, separate gauge supports or modules can be used for the cut pile hooks and the level cut loop looper or hook assemblies.

As further indicated in FIGS. 2A and 2B, each cut pile hook 32 generally includes a body 85 having a rear or shank portion, which generally can be received within a slot 87 or other similar opening formed through the body of the module or support 36, and further includes an extended, vertically oriented mid-portion and a horizontally extending throat portion 89 that terminates in a hooked or barbed front end 90. The hooked front end of each cut pile hook further can include a pickup area 91, which typically can be arranged along the same side as the pick-up areas of the level cut loop hooks, and the throat portions 89 of the cut pile hooks 32 further typically can be elongated so as to extend forwardly past the hooked forward ends of the level cut loop hooks 83, as indicated in FIG. 2A, for engaging the needles of the row of needles 17 (FIG. 1) arranged along the upstream side of the tufting zone T. Additionally, the mid-portions (FIG. 3B) of each cut pile hook 32 can have an extended height or configuration such that the throat portions of each of the cut pile hooks are spaced vertically above the row of adjacent level cut loop hooks 33 by a desired distance or elevation. Alternatively, the cut pile hooks can be mounted in slots or portions of their support or holder that are spaced vertically above the corresponding slots in which the level cut loop hooks are mounted in their holder, as shown in FIGS. 2A-4.

As also shown in FIGS. 2A and 2B, each of the level cut loop hooks 33 can be arranged along or substantially in line with a gap or gauge spacing 92 defined between each of the spaced cut pile hooks, and will further be spaced along the holder 86 so as to define gaps 93 therebetween, along which the cut pile hooks similarly can be aligned. The cut pile hooks 32 further generally will be aligned with a similar gap 94 or gauge spacing between the needles 18 (FIG. 4) of the second or downstream row of needles 18. As a result, as the cut pile hooks are reciprocated toward the tufting zone, their forward ends and throat portions can pass through the gaps between the needles 18 to engage corresponding ones of the needles 17 of the first or upstream row of needles. The needles 18 of the second row of needles similarly can pass through the gaps between the cut pile hooks, penetrating through the backing material to a depth or elevation where they are engaged by the level cut loop hooks, as shown in FIGS. 1, 3 and 4.

A series of knife assemblies 95 (FIG. 2B) further generally will be mounted in spaced series extending across the tufting machine, with each knife 95 in alignment with an associated or corresponding one of the cut pile hooks 32. Each knife assembly 95 typically will include a knife or cutting blade 96 mounted within a holder 97, which itself will be attached to a reciprocating drive that moves the knives into cutting engagement with the cut pile hooks so as to sever or cut any loops of yarns retained thereon to form cut pile tufts 14 in the backing material. The knives further can be of an opposite hand cutting to the pickups of their associates cut pile hooks, and can be mounted along the pickup sides of their cut pile hooks, while the needles 17 associated with such cut pile hooks can be aligned or oriented on the opposite sides thereof.

As also indicated in FIG. 2B, the knives or cutting blades 96 of the knife assemblies 95 for each of the cut pile hooks 32 additionally can be mounted at a slightly higher elevation than the knives 71 of the knife assemblies 70 for the level cut loop hooks 33 so as to facilitate cutting contact with the cut pile hooks. Alternatively, the knives 96 of the knife assemblies 95 for the cut pile hooks 32 can be of extended length, or can be mounted to a drive mechanism that extends the movement of the knives 96 as needed to ensure accurate cutting of the loops of yarns collected along the cut pile hooks for forming an additional series of cut pile tufts 16′, which can be formed with a different or varied pile height from the cut pile tufts 16 and/or the loop pile tufts 14/14′ formed by the level cut loop hooks as indicated in FIGS. 3 and 7.

Still a further embodiment of the method and system for forming tufted articles having variable loop pile and cut pile tufts formed therein according to the principles of the present invention is illustrated in FIGS. 5A-6. In this embodiment, multiple rows or sets of level cut loop looper or hook assemblies 200 can be arranged in a staggered and/or spaced relationship for selectively forming cut pile and loop pile tufts. For example, as indicated in FIG. 5A, a first series of level cut loop hooks 201 can be mounted with the throat portions 214 thereof located in a vertically spaced alignment at a first elevation above a second series of level cut loop hooks 202, the throat portions of which can be arranged or located at a second elevation, and with the first and second sets of level cut loop hooks generally being mounted along the downstream or cut pile side of the tufting machine as indicated in FIG. 6. In one embodiment, the first or upper level cut loop hooks 201 further can be positioned and configured to reach or extend through the gaps defined between the needles of a second or downstream row of the needles so as to engage the needles of a first or upstream row needles along the tufting zone T, while the second lower row or series of level cut loop hooks 202 (FIG. 5A) will engage the needles (FIG. 1) of the second or downstream row of needles. Alternatively, as shown in FIG. 6, in other embodiments, a single, in-line row of needles 18A can be mounted along a needle bar, which can be shifted transversely, and with the needles 18A having a length or being mounted so as to penetrate to a depth sufficient to be engaged by the second or lower series of level cut loop hooks. The level cut loop hooks 201 (FIGS. 5A and 6) further generally can be aligned with gaps 203 defined between the level cut loop hooks 202, which in turn can be aligned along gaps 204 defined between each of the level cut loop hooks 201, and through which the needles 18A can pass for engagement by the level cut loop hooks 202.

In the embodiment shown in FIGS. 5A-5B, the level cut loop hooks 201/202 can be mounted in spaced rows or series along a single module, holder or support 206. The holder or module 206 can have a body 207 with a front face 208, rear face 209, and a lower section 211 adapted to mount the support or holder 206 to a hook bar (not shown). The level cut loop hooks 201/202 generally will be received within slots 205 formed through the holder body 207 and extending from the front face 208 thereof to its rear face 209. Alternatively, the first and second rows of level cut loop hooks 201/202 can be mounted in separate holders or supports.

As also indicated in FIGS. 5A and 5B, each level cut loop hook 201 includes a body 212 having a rear or shank portion (not shown) that is received within one of the slots or other, similar openings formed through the body 207 of the holder 206, and further generally includes a vertically oriented mid-portion 213 and a horizontally extending throat portion 214 that terminates in a hooked or barbed front end 216. The hooked front end 216 of each level cut loop hook 201 also can include a pickup area, indicated at 217. The throat portions 214 of each of the level cut loop hooks of the first or upper row of level cut loop hooks 201 further can be arranged or formed so as to be spaced above the throats 221 of the level cut loop hooks 202 by a desired or defined pile differential or spacing, as indicated in FIGS. 5A and 5B, for engaging the needles 18A at a first, upper or reduced penetration depth thereof. As also indicated in FIG. 5A, the mid-portion 213 of each level cut loop hook 201 further can have an extended size or height so that the throat portions 214 of each of the level cut loop hooks 201 are spaced vertically above the lower row of level cut loop hooks 202. In a further alternative embodiment, the level cut loop hooks 201 can be mounted in slots in their module or support 206 that are spaced vertically above the corresponding slots in which the lower or second row of level cut loop hooks 202 are mounted in holder 206.

As shown in FIGS. 5A and 6, each of the lower or second row of level cut loop hooks 202 generally is arranged along a gap 204 between each of the spaced upper or first row of level cut loop hooks 201, and further generally will be positioned at a lower elevation than the level cut loop hooks 201. Each of the level cut loop hooks 202 similarly includes a body 218 having a rear or shank portion that extends rearwardly through a slot or other opening formed in the holder 206, and a vertically extending mid-portion 219. A tapered throat portion 221 extends forwardly from the mid-portion 219 and terminates at a hooked forward or distal end 222. Each of the level cut loop hooks 202 further generally can include a pickup area 223, which pickup area 223 typically can be arranged along the same side of the level cut loop hooks 202 as the pickup areas 217 for the level cut loop hooks 201. Additionally, as indicated in FIG. 5B, the level cut loop hooks 202 of the second or lower series of level cut loop hooks typically can have throat portions 221 arranged at a lower elevation or which can be shorter than the throat portions 214 of the first or upper level cut loop hooks 201 so as to be in position to engage the needles 18A (FIG. 6) or otherwise configured at a second, lower or increased penetration depth of the needles, during a tufting operation. The needles 18A further can be shifted transversely to provide for formation of other, varied pattern effects.

Each of the level cut loop hooks 201/202 (FIGS. 5A-5B) further will include extensible clips 224 that are moveable along the bodies of the level cut loop hooks 201/202 through the holder 206 in the direction of arrows 226 and 226′ (FIG. 5B). Each clip generally includes an elongated body 227 with a tapered forward or first end 228, and a hooked or curved second or rear end 229 that projects from the rear side or face 209 of the holder 206. As discussed above, actuators, such as hydraulic or pneumatically operated cylinders 56 mounted in an array behind the level cut loop hooks, attach to and/or engage the rear or second ends 229 of each of the clips 224. The actuators can be selectively engaged so as to cause the associated clips 224 to be moved between an extended position, with the front or first end portion 228 of each clip positioned adjacent and extending beneath the hooked front end 216 of its associated level cut loop hook 201 and 202, and a retracted position wherein the front or first ends 228 of such clips are retracted rearwardly from the hooked front ends of their associated level cut loop hooks.

In their extended positions, the clips can substantially block or prevent loops of yarn picked from the needles from being captured and/or retained behind the hooked front ends and along the throat portions of each of the level cut loop hooks. The loops of yarns picked from the needles thus can be pulled off of the level cut loop hooks as they are reciprocated away from the needles for forming loop pile tufts in the backing material, which loop pile tufts can be formed with varied or different pile heights that can be based on the elevation differential between the level cut loop hooks 201/202, and by further operation of control of the yarn feed to the needles forming such loop pile tufts. When the clips are in their retracted positions, the loops of yarns picked from the needles will be captured behind the hooked front ends and along the throat portions of the level cut loop hooks 201/202, where they typically will be cut by a knife assembly 230/230′ (FIG. 5B) to form cut pile tufts, which cut pile tufts further can be formed with varied or different pile heights that similarly can be based on the elevation differential between the level cut loop hooks 201/202, and which can be of different pile heights from the loop pile tufts formed in the tufted article.

As indicated in FIGS. 5-6B, a series of knife assemblies 230/230′ generally will be mounted in spaced series extending across the tufting machine. Each knife assembly generally will be aligned with one of the level cut loop hooks 201 or 202, and each typically includes a knife or cutting blade 231 mounted within a holder 232 attached to a reciprocating drive mechanism. The drive mechanism moves the knives into cutting engagement with the level cut loop hooks 201/202 so as to sever or cut any loops of yarns retained along the throats thereof to form cut pile tufts in the backing material. As discussed previously, each of the knives can be of the same or an opposite hand cutting to the pickups of their associated level cut loop hooks 201/202. The knives also can be mounted along the pickup sides of their associated level cut loop hooks, on the opposite sides of their level cut loop hooks from the needles associated therewith.

The knives or cutting blades 231 of the knife assemblies 230 for each of the first or level cut loop hooks 201 further can be mounted at a slightly higher elevation than the knives of knife assemblies 230′ for the second or lower level cut lop hooks 202, as indicated in FIG. 5B, so as to ensure sufficient cutting contact with the level cut loop hooks 201. Alternatively, the knives 231 of the knife assemblies 230 for the level cut loop hooks 201 can be of an extended length, or mounted to a drive mechanism that extends the movement of the knives as needed to ensure accurate cutting of the loops of yarns collected along the level cut loop hooks as needed for forming additional cut pile tufts.

The present invention thus enables varying arrangements of loop pile loopers, cut pile hooks, and level cut loop hooks, which can be arranged to pass through gaps defined therebetween and/or between adjacent needles, substantially with the incidence of previously sewn loops of yarn being engaged by the level cut loop hooks during the production of finer or smaller gauge (i.e., 5/32- 1/16 gauge) carpets being minimized, while allowing the formation of varying cut and/or loop and level cut loop pile tufted pattern effects in the same backing fabric or carpet, including the formation of cut and loop pile tufts having differing, variable pile heights. The present invention further enables the stagger between rows of needles to be reduced to as short as approximately ½ inch—approximately ¼ inch or less without the knives engaging the previously sewn loops or otherwise engaging and interfering with the operation of the loopers. As a result, given the reduction in the stagger, the problems of side matching, i.e., matching of the left and right seam of a carpet, are minimized since the stagger can be reduced, which correspondingly reduces the stretching and/or necking of the backing material as the backing material passes passing through the tufting zone. The use of varying yarn feeds also enables formation of further variable pile height loop pile tufts together with variable pile height cut pile tufts in the same carpet or tufted article.

The foregoing description generally illustrates and describes various embodiments of the present invention. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present invention without departing from the spirit and scope of the invention as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present invention. It therefore will be understood by those skilled in the art that while the present invention has been described above with reference to preferred embodiments, numerous variations, modifications, and additions can be made thereto without departing from the spirit and scope of the present invention as set forth in the following claims. Accordingly, various features and characteristics of the present invention as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the invention, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims. 

What is claimed is:
 1. A tufting machine for forming spaced rows of loop pile tufts and cut pile tufts having varying pile heights in a backing, comprising: a first row of needles located along an upstream side of a tufting zone of the tufting machine, and a second row of needles located along a downstream side of the tufting zone, said needles of said first and second rows of needles carrying yarns therewith as said needles are reciprocated into the backing; a series of level cut loop hooks movable into engagement with said needles of said second row of needles so as to form loops of yarns, said level cut loop hooks each having a clip movable between extended and retracted positions, said clips being selectively actuated to retard retention of loops of yarns by selected ones of said level cut loop hooks to form loop pile tufts; a first series of knives moveable into engagement with said level cut loop hooks for cutting the loops of yarns retained by said level cut loop hooks to form cut pile tufts in the backing when said clips are in their retracted position; a series of cut pile hooks positioned along the tufting zone at a different elevation from said level cut loop hooks, said cut pile hooks movable into engagement with said needles of said first row of needles to pick loops of the yarns therefrom; and a second series of knives movable into engagement with said cut pile hooks for cutting the loops of yarns picked by said cut pile hooks to form cut pile tufts in the backing having a different pile height than the loop pile tufts and/or the cut pile tufts formed by said level cut loop hooks.
 2. The tufting machine of claim 1 and wherein said knives of said first series of knives are of an opposite hand cutting to the pickup of said level cut loop hooks.
 3. The tufting machine of claim 2 and wherein said knives of said first series of knives each are positioned along a pickup side of an associated one of said level cut loop hooks.
 4. The tufting machine of claim 1 and wherein said needles of said first and second rows of needles are spaced at least approximately 5/32 inch apart.
 5. The tufting machine of claim 1 and wherein said level cut loop hooks are positioned at an elevation that is vertically spaced below said cut pile hooks, and wherein said level cut loop hooks are each substantially aligned with a gap defined between adjacent ones of said cut pile hooks and through which said needles of said second row of needles pass for engagement with said level cut loop hooks, and wherein said cut pile hooks are each substantially aligned with a gap defined between each of said needles of said second row of needles such that said cut pile hooks pass between adjacent needles of said second row of needles to engage said needles of said first row of needles.
 6. A method of forming spaced rows of cut pile and loop pile tufts in a base fabric, comprising: moving the base fabric along a path of travel through a tufting machine; engaging the base fabric with first and second rows of needles carrying a plurality of yarns; as the first and second rows of needles penetrate the base fabric moving a plurality of cut pile hooks between the needles of the second row of needles and into engagement with the needles of the first row of needles to form loops of yarns on the cut pile hooks; moving a plurality of level cut loop hooks, located at a different elevation from the cut pile hooks, into engagement with the needles of the second row of needles so as to form loops of yarns along the level cut loop hooks; moving clips associated with selected ones of the level cut loop hooks from a retracted position to an extended position, wherein retention of the loops of yarns formed from the second plurality of yarns carried by the needles of the second row of needles is substantially blocked, to selectively form loop pile tufts of yarns in the base fabric; and moving a series of knives into engagement with the loops of yarns retained along the cut pile hooks and along non-selected ones of the level cut loop hooks to form cut pile tufts of yarns in the base fabric.
 7. The method of claim 6, wherein the knives associated with each level cut loop hook are positioned on an opposite side of each level cut loop hook from an associated one of the needles of the second row of needles.
 8. The method of claim 6, further comprising staggering the first and second rows of needles up to approximately ½ inch apart.
 9. The method of claim 6, further comprising releasing the loops of yarns formed along the selected ones of the level cut loop hooks as the selected level cut loop hooks are reciprocated away from the needles of the second row of needles when the clips of the selected ones of the level cut loop hooks are in an extended position to form the loop pile tufts.
 10. The method of claim 6, wherein the knives each have opposite hand cutting to pickups of the cut pile hooks and/or the level cut loop hooks associated therewith.
 11. The method of claim 6, further comprising moving the second row of needles through gaps defined between each of the cut pile hooks to a penetration depth below the cut pile hooks for engagement by the level cut loop hooks.
 12. The method of claim 11, further comprising moving the first row of needles through the base fabric to a penetration depth less than the penetration depth of the second row of needles so as to form cut pile tufts at a different pile height than the cut pile and loop pile tufts formed by the level cut loop hooks.
 13. A method of forming tufted articles having cut pile tufts and loop pile tufts, comprising: reciprocating a series of needles, each carrying a plurality of yarns, into and out of a backing moving through a tufting zone; moving a first series of level cut loop hooks having throat portions located at a first elevation into engagement with the needles at a first penetration depth of the needles to pull loops of yarn therefrom; moving a second series of level cut loop hooks, each having a throat portion located at a second elevation vertically spaced from the throat portions of the first level cut loop hooks, into engagement with the needles at a second penetration depth pull loops of yarns therefrom; cutting loops of yarns retained along non-selected ones of the first and/or second series of level cut loop hooks, whose clips are in a non-engaging position, with a series of knives to form cut pile tufts; moving clips associated with selected ones of the first and/or second series of level cut loop hooks into engaging positions wherein the loops of yarn engaged and pulled from the needles by the selected ones of the first and/or second series of level cut loop hooks are substantially prevented from being retained along the selected ones of the first and/or second series of level cut loop hooks to form loop pile tufts; and wherein the cut pile tufts and loop pile tufts formed by the first and second series of level cut loop hooks are formed with different pile heights.
 14. The method of claim 13, wherein engaging the loops of yarns comprises moving each of the knives along pickup sides of each level cut loop hook associated therewith.
 15. The method of claim 14 and wherein the knives are of an opposite hand cutting to the pickup of the level cut loop hooks.
 16. The method of claim 13 and further comprising shifting the needles transversely with respect to the backing moving through the tufting zone.
 17. A tufting machine for forming loop pile and cut loop pile tufts in a backing material passing therethrough, comprising: at least one row of needles extending in spaced series across at least one reciprocating needle bar, and carrying a series of yarns into the backing material as said at least one needle bar is reciprocated; a first plurality of level cut loop hooks, each having a throat arranged at a first elevation below the backing material, and movable into engagement with said needles at a first penetration depth of said needles to form and pick loops of yarns therefrom; a second plurality of level cut loop hooks each having a throat arranged at a second elevation below the backing material, spaced vertically from said throats of said first plurality of level cut loop hooks and movable into engagement with said needles at a second penetration depth that is different from said first penetration depth of said needles to form and pick loops of yarns therefrom; clips arranged along each of said level cut loop hooks of said first and second pluralities of level cut loop hooks, said clips movable between extended and retracted positions to selectively form the loop pile and cut pile tufts in the backing material; and knives associated with each of said level cut loop hooks of said first and second pluralities of level cut loop hooks and movable into engagement therewith for cutting loops of yarns retained along said first and second pluralities of level cut loop hooks to form the cut pile tufts; wherein the cut and loop pile tufts formed by said first plurality of level cut loop hooks are formed at a different pile height from the cut and loop pile tufts formed by said second plurality of level cut loop hooks.
 18. The tufting machine of claim 17, wherein throats of said second first plurality of level cut loop hooks are spaced below said first plurality of level cut loop hooks and are substantially aligned with gaps defined between said level cut loop hooks of said first plurality of level cut loop hooks; and wherein said needles of said second row of needles pass between gaps defined between each of said first plurality of level cut loop hooks for engagement by said second plurality of level cut loop hooks.
 19. The tufting machine of claim 17, wherein said knives of are positioned along a pickup side of their associated level cut loop hooks.
 20. The tufting machine of claim 19, wherein said knives of an opposite hand cutting to the pickup of their associated level cut loop hook. 